Device for collecting refrigerant leaking from an appliance

ABSTRACT

A heating, ventilation, and air conditioning system including a heat exchanger assembly and a refrigerant collection device. The refrigerant collection device has a body axially aligned with a perimeter of the heat exchanger assembly. The body has at least one channel formed therein to capture a refrigerant and direct the captured refrigerant to a detection location of the body.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.63/240,521 filed Sep. 3, 2021, the disclosure of which is incorporatedherein by reference in its entirety.

BACKGROUND

Exemplary embodiments of the present disclosure relate to heating,ventilation, and air conditioning (HVAC) systems, and more particularly,to a device for use with a HVAC system to facilitate detection and safemitigation of a refrigerant leak.

Refrigeration systems, as used in HVAC applications, utilize refrigerantwithin a closed loop circuit to condition air provided to an area orenclosed space. This refrigerant, historically, has been provided as afluid with a high global warming potential (GWP) value such as R134A orR410A. Thus, although the refrigerants that have been used previouslyare effective coolants, the negative effect they can have on theenvironment has led to regulatory requirements to transition torefrigerants which have moderate-to-low GWP values.

Modem refrigerants, for example A2L refrigerants, comply withenvironmental regulations relating to global warming potential (GWP). Inorder to comply with the proposed GWP regulations, hydrofluorocarbon(HFC) and hydrocarbon refrigerants with various levels of flammabilityare being developed and are being considered for use in HVAC systems.

As with any system, there is a potential for flammable refrigerants usedin 1-IVAC applications to leak and migrate to undesirable areas in thevicinity of the HVAC system that may contain an ignition source. Whenthe flammable refrigerants, in the presence of air or another oxidizer,are exposed to an ignition source, the potential for a combustion eventexists.

BRIEF DESCRIPTION

According to an embodiment, a heating, ventilation, and air conditioningsystem including a heat exchanger assembly and a refrigerant collectiondevice. The refrigerant collection device has a body axially alignedwith a perimeter of the heat exchanger assembly. The body has at leastone channel formed therein to capture a refrigerant and direct thecaptured refrigerant to a detection location of the body.

In addition to one or more of the features described above, or as analternative to any of the foregoing embodiments the body has a generallyhorizontal configuration relative to the heat exchanger assembly.

In addition to one or more of the features described above, or as analternative to any of the foregoing embodiments the body has a generallysloped configuration relative to the heat exchanger assembly.

In addition to one or more of the features described above, or as analternative to any of the foregoing embodiments the at least one channelhaving a base and at least one sidewall extending at an angle from thebase.

In addition to one or more of the features described above, or as analternative to any of the foregoing embodiments a configuration of theat least one channel varies about the body of the refrigerant collectiondevice.

In addition to one or more of the features described above, or as analternative to any of the foregoing embodiments the at least onesidewall includes an inward sidewall and an outward sidewall arranged atopposite sides of the base.

In addition to one or more of the features described above, or as analternative to any of the foregoing embodiments the outward sidewall isformed by another component of the HVAC system.

In addition to one or more of the features described above, or as analternative to any of the foregoing embodiments a height of the inwardsidewall is different than a height of the outward sidewall.

In addition to one or more of the features described above, or as analternative to any of the foregoing embodiments the at least one channelincludes a front portion, a back portion, and a side portion fluidlyconnecting the front portion and the back portion.

In addition to one or more of the features described above, or as analternative to any of the foregoing embodiments comprising at least onecross-piece extending between and fluidly connected to the front portionand the back portion of the at least one channel.

In addition to one or more of the features described above, or as analternative to any of the foregoing embodiments the at least onecross-piece has a V-shape.

In addition to one or more of the features described above, or as analternative to any of the foregoing embodiments the at least onecross-piece is vertically offset from the base of the at least onechannel.

In addition to one or more of the features described above, or as analternative to any of the foregoing embodiments the heat exchangerassembly further comprises a tube bank and the at least one cross-pieceis axially aligned with a central portion of the tube bank.

In addition to one or more of the features described above, or as analternative to any of the foregoing embodiments the heat exchangerassembly further comprises a condensate drain pan and the body of therefrigerant collection device is coupled to the condensate drain pan.

In addition to one or more of the features described above, or as analternative to any of the foregoing embodiments the heat exchangerassembly further comprises a condensate drain pan and the body of therefrigerant collection device is integrally formed with the condensatedrain pan.

In addition to one or more of the features described above, or as analternative to any of the foregoing embodiments the heat exchangerassembly includes an apex and the body of the refrigerant collectiondevice includes a plurality of cutouts, the apex being receivable withinthe plurality of cutouts.

In addition to one or more of the features described above, or as analternative to any of the foregoing embodiments the body of therefrigerant collection device is formed from a plurality of separatepieces.

In addition to one or more of the features described above, or as analternative to any of the foregoing embodiments the heat exchangerassembly includes an apex, and the plurality of separate pieces includesa first piece and a second piece, the first piece extending from theapex in a first direction and the second piece extending from the apexin a second, opposite direction.

In addition to one or more of the features described above, or as analternative to any of the foregoing embodiments the second piece is amirror image of the first piece.

In addition to one or more of the features described above, or as analternative to any of the foregoing embodiments comprising a detectionsensor mounted to the refrigerant collection device adjacent to thedetection location.

BRIEF DESCRIPTION OF THE DRAWINGS

The following descriptions should not be considered limiting in any way.With reference to the accompanying drawings, like elements are numberedalike:

FIG. 1 is a schematic diagram of an exemplary HVAC system, depicted as afurnace coil or fan coil unit, according to an embodiment;

FIG. 2 is a perspective view of an exemplary refrigerant collectiondevice for use in a HVAC system, such as a furnace coil or fan coilunit, according to an embodiment;

FIG. 3 is a perspective view of an exemplary refrigerant collectiondevice for use in a HVAC system, such as a furnace coil or fan coilunit, according to an embodiment;

FIG. 4 is a perspective view of another exemplary refrigerant collectiondevice for use in a HVAC system, such as a furnace coil or fan coilunit, according to an embodiment;

FIG. 5 is a perspective view of yet another exemplary refrigerantcollection device for use in a HVAC system, such as a furnace coil orfan coil unit, according to an embodiment; and

FIG. 6 is a perspective view of a refrigerant collection deviceinstalled within a furnace coil or fan coil unit according to anembodiment.

DETAILED DESCRIPTION

A detailed description of one or more embodiments of the disclosedapparatus and method are presented herein by way of exemplification andnot limitation with reference to the Figures.

With reference now to FIG. 1 , an example of a heating, ventilation, andair conditioning (HVAC) system 20 is illustrated, depicted as a furnacecoil or fan coil unit 20. Although described herein as furnace or fancoil unit it should be appreciated that the HVAC; system 20 may be anyheating or cooling system. As shown, the furnace coil or fan coil unit20 includes a cabinet or housing duct 22 within which various componentsof the HVAC system are located. For example, housed within the cabinet22 of the furnace coil or fan coil unit 20 is a heat exchanger assembly24 configured to heat and/or cool the adjacent air. A blower or fanassembly 26 may also be arranged within the cabinet 22 or alternatively,at a position outside of but in fluid communication with the cabinet 22.The blower 26 is operable to circulate a flow of air A through theinterior of the cabinet 22, across the heat exchanger assembly 24.Depending on the desired characteristics of the furnace coil or fan coilunit 20, the blower 26 may be positioned either downstream with respectto the heat exchanger assembly 24 (i.e., a “draw through”configuration), or upstream with respect to the heat exchanger assembly24 (i.e., a “blow through” configuration), as shown in FIG. 1 .

The heat exchanger assembly 24 may include any of a plurality ofconfigurations. As illustrated in FIG. 1 , the heat exchanger assembly24 includes one or more heat exchanger coils 28 arranged in a non-linearconfiguration. For example, the heat exchanger assembly 24 may have agenerally V-shaped configuration, a generally A-shaped configuration, ora generally N-shaped configuration, as is known in the art. In otherembodiments, the heat exchanger assembly 24 may include a single heatexchanger coil 28 arranged at an angle with respect to the flow path ofair A through the cabinet 22. In embodiments where the furnace coil orfan coil unit 20 is configured to provide cool air, the heat exchangerassembly 24 absorbs heat from the air A passing through the heatexchanger assembly 24 and the resultant cool air A is provided to aspace to be conditioned.

As shown, the furnace coil or fan coil unit 20 typically includes acondensate drain pan 30 arranged adjacent to the heat exchanger assembly24 within the cabinet 22, such as at the lower side of the heatexchanger assembly 24 for example. As the air A flowing through the heatexchanger assembly 24 is cooled, a portion of the water within the flowof air A may condense and collect on the surfaces of the heat exchangercoil(s) 28. Gravity and continued air flow through the heat exchangerassembly 24 may cause a portion of this condensation to fall from theheat exchanger assembly 24 onto the drain pain 30.

With continued reference to FIG. 1 , the refrigerant circulating withinthe heat exchanger assembly 24 may, in rare instances, leak. Whenutilizing A2L refrigerants, a leak of refrigerant could lead toundesirable consequences due to the mildly flammable nature of A2Lrefrigerants. Accordingly, the furnace coil or fan coil unit 20 mayinclude at least one detection sensor or assembly 32 operable to detecta refrigerant leak therein. Examples of the detection sensor or assembly32 include, but are not limited to a point sensor and a line of sight orbeam sensor. Further, the technologies used by one or more detectionsensors may include non-dispersive infrared (NDIR), photoacousticspectroscopy (PAS), quantum cascade laser spectroscopy (QCLS), tunablediode laser spectroscopy (TDLS), thermal conductivity (TC), metal oxidesemiconductor (MOS), ultrasonic, speed of sound, and ultravioletspectroscopy for example. However, it should be understood that anysuitable type of detection sensor or assembly 32 is within the scope ofthe disclosure.

In an embodiment, a refrigerant collection device 40 is located withinthe cabinet 22, adjacent to the heat exchanger assembly 24, and the oneor more detection sensors 32 are mounted at or directly adjacent to aportion of the refrigerant collection device 40. With reference now toFIGS. 2-6 , various examples of a refrigerant collection device 40intended to capture refrigerant and direct an adequate amount ofrefrigerant to a detection location as it leaks from the heat exchangerassembly 24 are illustrated in more detail. In each of the illustrated,non-limiting embodiments, the refrigerant collection device 40 is shownas being located adjacent to an inner periphery of the cabinet 22, inaxial alignment with a perimeter or periphery of the heat exchangerassembly 24. The refrigerant collection device 40 has a substantiallyhollow interior 41 to minimize interference with the flow through thefurnace coil or fan coil unit, and more specifically, the heat exchangerassembly 24. In each of the illustrated embodiments, the refrigerantcollection device 40 is configured to wrap about the entire innerperiphery of the cabinet 22 (i.e., across the front 22 a, back 22 b andtwo sides 22 c, 22 d thereof). However, it should be understood thatembodiments where the refrigerant collection device 40 extends aboutonly a portion of the perimeter of the heat exchanger assembly 24 and/orthe inner periphery of the cabinet 22 are also within the scope of thedisclosure.

The refrigerant collection device 40 may be formed as a singlecomponent, as shown in FIGS. 2-4 . When formed as a single component,the body 42 of the refrigerant collection device 40 may have one or morecutouts 44 formed therein complementary to a portion of the heatexchanger assembly 24. In the illustrated, non-limiting embodiments ofFIGS. 2 and 4 , the plurality of cutouts 44 formed in the refrigerantcollection device 40 are axially aligned with one another and aregenerally complementary to the contour of the apex 25, such as formed bya bend or header for example, of the heat exchanger assembly 24.Accordingly, when the refrigerant collection device 40 is installedwithin the cabinet, the apex 25 of the heat exchanger assembly 24 may bepositioned therein.

In other embodiments, the body 42 refrigerant collection device 40 maybe formed by a plurality of pieces. In the non-limiting embodiment ofFIG. 5 , the refrigerant collection device 40 includes a first piece 42a and a second piece 42 b, the first piece 42 a and the second piece 42b being disposed at opposite sides of the heat exchanger assembly 24. Insuch embodiments, the first piece 42 a may extend in a first directionfrom the apex 25 of the heat exchanger assembly, and the second piece 42b may extend from the apex 25 in a second direction. In suchembodiments, the first piece 42 a and the second piece 42 b may besubstantially identical, or alternatively, the first piece 42 a may be amirror image of the second piece 42 b. Further, the first piece 42 a andthe second piece 42 b may be separated or offset from one another whenmounted within the cabinet 22 (FIG. 5 ), or alternatively, may beconfigured to couple to or overlap with one another. It should beunderstood that configurations of the refrigerant collection device 40having any number of pieces 42, such as more than two pieces forexample, having similar or different configurations, are also within thescope of the disclosure.

As shown, the body 42 or one or more of the pieces 42 a, 42 b that formthe body of the refrigerant collection device 40 includes at least onechannel 50 within which refrigerant leaking from the heat exchangerassembly 24 is collected and directed. In some embodiments, the body 42or pieces thereof, have a plurality of channels for collectingrefrigerant. In other embodiments, the body 42 or pieces 42 a, 42 b mayeach have a single channel 50 that extends continuously about each ofthe sides of the body 42 or respective pieces 42 a, 42 b of therefrigerant collection device 40. Accordingly, channel 50 of therefrigerant collection device 40 may have a front portion 50 a, a backportion 50 b, and one or more side portions 50 c, each of which may beconfigured to fluidly connect the front portion 50 a and the backportion 50 b. The channel 50 typically has a base 52, for exampleoriented at an angle to one of the sides of the cabinet 22, and at leastone sidewall extending at an angle from the base 52. In an embodiment,the channel 50 includes both an inward sidewall 54 and an outwardsidewall 56 arranged at opposite sides of the base 52. The inwardsidewall 54 and the outward sidewall 56 may be arranged generallyparallel to one another, or alternatively, may be arranged at a non-zeroangle to one another.

In the illustrated, non-limiting embodiment, the base 52 of each portion50 a-50 c of the channel 50 is arranged within the same plane. However,it should be understood that embodiments where the orientation of thechannel 50 varies are also contemplated herein. For example, the base 52of one or more of the portions 50 a-50 c of the channels 50 may beslanted relative to a horizontal plane, for example to facilitate theflow of the liquid within the channel to a desired location within thechannel 50.

The inward sidewall 54, base 52, and outward sidewall 56 of a portion 50a-50 c of the channel 50 may be integrally formed, such as by bending apiece of sheet metal for example. However, embodiments where the inwardsidewall 54, outward sidewall 56, and base 52 are not integrally formedare also contemplated herein. Further, embodiments where at least aportion of the refrigerant collection device 40, such as the outwardsidewall 56 of at least a portion of the channel 50 for example, isformed by another component of the furnace coil or fan coil unit 20,such as a wall 22 a-22 d of the cabinet 22, or a portion of thecondensate drain pan 30 for example, are also within the scope of thedisclosure.

The width of the channel 50, measured as the width of the base 52extending between the inward sidewall 54 and the outward sidewall 56 ata location, may be substantially constant about the body or respectivepieces 42 of the refrigerant collection device 40, or alternatively, mayvary. For example, a width of the front portion 50 a of the channel 50may be greater than the width of the back portion 50 b of the channel50. However, it should be understood that this variation may depend onthe position of the one or more detection sensors 32 relative to therefrigerant collection device 40 to facilitate the flow of capturedrefrigerant within the channel 50 toward a detection location containingor adjacent to the one or more detection sensors 32. Further, a heightof at least one of the inward sidewall 54 and the outward sidewall 56may be substantially constant about the perimeter of the channel 50.However, in other embodiments best shown in FIG. 4 , a height of one orboth of the inward sidewall 54 and the outward sidewall 56 may varyabout the perimeter of the channel 50. For example, the height of theinward sidewall 54 may gradually decrease towards the corners of thechannel 50.

In the illustrated, non-limiting embodiment, a maximum height of theinward sidewall 54 relative to the base 52, measured parallel to thelongitudinal axis of the cabinet 22 and the direction of air flow Athrough the cabinet 22, is greater than the maximum height of theoutward sidewall 56 relative to the base 52. In other embodiments,however, the maximum height of the inward sidewall 54 may be less thanor equal to the maximum height of the outward sidewall 56.

With reference to FIGS. 2 and 3 , the refrigerant collection device 40may additionally include at least one cross-piece 60. In theillustrated, non-limiting embodiment, the at least one cross-piece 60extends between an opening 61 formed in the inward sidewall 54 at theback portion of the channel 50 and an opening 61 formed in the inwardsidewall 54 at the front portion 50 a of the channel 50. The at leastone cross-piece 60 is illustrated as being arranged generally parallelto the adjacent sides 22 c, 22 d of the cabinet 22 and the side portion50 c of the channel 50; however, embodiments where the at least onecross-piece 60 is arranged at an angle to one or both the side 22 c, 22d of the cabinet 22 and the side portion 50 c of the channel 50 arewithin the scope of the disclosure. Further, although the at least onecross-piece 60 is shown as being generally centrally located between theapex 25 of the heat exchanger assembly 24 and the inward sidewall 54 ofthe side portion 50 c of the channel 50, axially aligned with a centralportion of the tube bank of the heat exchanger assembly 24, embodimentswhere at least one cross-piece 60 is skewed towards either the apex 25or towards the inward sidewall 54 of the side portion of the channel 50are contemplated herein.

The at least one cross-piece 60 may similarly have a cavity 62 orchannel-like configuration. In the illustrated, non-limiting embodiment,the at least one cross-piece has a generally V-shaped configuration. Byusing a V-shape, the interference of the cross-piece with the air flow Athrough the cabinet 22 is minimized; however, any suitable shapedefining a cavity 62 for receiving refrigerant is within the scope ofthe disclosure. Further, the at least one cross-piece 60 is arranged influid communication with one or both of the front portion 50 a and theback portion 50 b of the channel 50. To facilitate the flow ofrefrigerant from the cross-piece 60 to either the front portion 50 a andthe back portion 50 b of the channel 50, the bottom of the cross-piece60 may be elevated relative to the base 52 of the channel 50.Alternatively, or in addition, the at least one cross-piece 60 may havea generally horizontal configuration as shown, or may be angled relativeto one or both the front portion 50 a and the back portion 50 b of thechannel 50. For example, the height of the opening 61 formed in theinward sidewall 54 at the back portion 50 b of the channel 50 may begreater than the height of the opening 61 formed in the inward sidewall54 at the front portion 50 a of the channel 50 such that the cross-piece60 is sloped downwardly towards the front portion 50 a of the channel50. In other embodiments, the center of the cross-piece 60 may be higherthan the ends of the cross-piece 60 such that the cross-piece 60 issloped downwardly towards both the front portion 50 a and the backportion 50 b.

When the refrigerant collection device 40 is mounted within the cabinet22, the base 52 of the channel 50, or at least a portion thereof, mayhave a generally horizontal configuration. However, in otherembodiments, the refrigerant collection device may be mounted with agenerally sloped configuration such that any liquid collected within thechannel 50 is configured to flow in a desired manner via gravity.Further, although the refrigerant collection device is illustrated asbeing at generally the same vertical height as the condensate drain pan30, embodiments where the refrigerant collection device 40 is verticallyoffset from the condensate drain pan 30 are also within the scope of thedisclosure.

A refrigerant collection device 40 as described herein is configured tocapture an adequate amount of leaking refrigerant as it falls from anylocation of the heat exchanger assembly 24 and in any directiontherefrom and direct the collected refrigerant towards the detectionsensor for enhanced leak detection. The refrigerant collection device 40may further be designed to position the detection sensors 32 at alocation that is easily accessible by field technicians. Further, inembodiments where the furnace coil or fan coil unit 20 is arrangedadjacent to a furnace, the refrigerant collection device 40 additionallyprovides a protective barrier for shielding electronics from the heatemitted from the furnace heat exchanger.

The term “about” is intended to include the degree of error associatedwith measurement of the particular quantity based upon the equipmentavailable at the time of filing the application.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the presentdisclosure. As used herein, the singular forms “a”, “an” and “the” areintended to include the plural forms as well, unless the context clearlyindicates otherwise. It will be further understood that the terms“comprises” and/or “comprising,” when used in this specification,specify the presence of stated features, integers, steps, operations,elements, and/or components, but do not preclude the presence oraddition of one or more other features, integers, steps, operations,element components, and/or groups thereof.

While the present disclosure has been described with reference to anexemplary embodiment or embodiments, it will be understood by thoseskilled in the art that various changes may be made and equivalents maybe substituted for elements thereof without departing from the scope ofthe present disclosure. In addition, many modifications may be made toadapt a particular situation or material to the teachings of the presentdisclosure without departing from the essential scope thereof.Therefore, it is intended that the present disclosure not be limited tothe particular embodiment disclosed as the best mode contemplated forcarrying out this present disclosure, but that the present disclosurewill include all embodiments falling within the scope of the claims.

What is claimed is:
 1. A heating, ventilation, and air conditioning(HVAC) system comprising: a heat exchanger assembly; a refrigerantcollection device having a body axially aligned with a perimeter of theheat exchanger assembly, the body having at least one channel formedtherein to capture a refrigerant, wherein the body is configured todirect captured refrigerant to a detection location of the body.
 2. TheHVAC system of claim 1, wherein the body has a generally horizontalconfiguration relative to the heat exchanger assembly.
 3. The HVACsystem of claim 1, wherein the body has a generally sloped configurationrelative to the heat exchanger assembly.
 4. The HVAC system of claim 1,wherein the at least one channel having a base and at least one sidewallextending at an angle from the base.
 5. The HVAC system of claim 4,wherein a configuration of the at least one channel varies about thebody of the refrigerant collection device.
 6. The HVAC system of claim4, wherein the at least one sidewall includes an inward sidewall and anoutward sidewall arranged at opposite sides of the base.
 7. The HVACsystem of claim 6, wherein the outward sidewall is formed by anothercomponent of the HVAC system.
 8. The HVAC system of claim 6, wherein aheight of the inward sidewall is different than a height of the outwardsidewall.
 9. The HVAC system of claim 4, wherein the at least onechannel includes a front portion, a back portion, and a side portionfluidly connecting the front portion and the back portion.
 10. The HVACsystem of claim 9, further comprising at least one cross piece extendingbetween and fluidly connected to the front portion and the back portionof the at least one channel.
 11. The HVAC system of claim 10, whereinthe at least one cross-piece has a V-shape.
 12. The HVAC system of claim10, wherein the at least one cross-piece is vertically offset from thebase of the at least one channel.
 13. The HVAC system of claim 10,wherein the heat exchanger assembly further comprises a tube bank andthe at least one cross-piece is axially aligned with a central portionof the tube bank.
 14. The HVAC system of claim 1, wherein the heatexchanger assembly further comprises a condensate drain pan and the bodyof the refrigerant collection device is coupled to the condensate drainpan.
 15. The HVAC system of claim 1, wherein the heat exchanger assemblyfurther comprises a condensate drain pan and the body of the refrigerantcollection device is integrally formed with the condensate drain pan.16. The HVAC system of claim 1, wherein the heat exchanger assemblyincludes an apex and the body of the refrigerant collection deviceincludes a plurality of cutouts, the apex being receivable within theplurality of cutouts.
 17. The HVAC system of claim 1, wherein the bodyof the refrigerant collection device is formed from a plurality ofseparate pieces.
 18. The HVAC system of claim 17, wherein the heatexchanger assembly includes an apex, and the plurality of separatepieces includes a first piece and a second piece, the first pieceextending from the apex in a first direction and the second pieceextending from the apex in a second, opposite direction.
 19. The HVACsystem of claim 18, wherein the second piece is a mirror image of thefirst piece.
 20. The HVAC system of claim 1, further comprising adetection sensor mounted to the refrigerant collection device adjacentto the detection location.